Boiler Operator’s Guide, 5th Edition PDF by Ray Wohlfarth and Anthony L Kohan


Boiler Operator’s Guide, Fifth Edition

By Ray Wohlfarth and Anthony L Kohan

Boiler Operator’s Guide, Fifth Edition



Abbreviations and Symbols

Chapter 1 Boiler Systems, Classifications, and Fundamental

Operating Practices

Questions and Answers

Chapter 2 Firetube Boilers

Questions and Answers

Chapter 3 Watertube Boilers

Questions and Answers

Chapter 4 Electric and Special Application Boilers

Questions and Answers

Chapter 5 Nuclear Power Plant Steam Generators

Questions and Answers

Chapter 6 Material Structure, Required Code Material, and


Questions and Answers

Chapter 7 Fabrication by Welding and NDT

Questions and Answers

Chapter 8 Material Testing, Stresses, and Service Effects

Questions and Answers

Chapter 9 Code Strength, Stress, and Allowable Pressure


Questions and Answers

Chapter 10 Boiler Connections, Appurtenances, and Controls

Questions and Answers

Chapter 11 Combustion, Burners, Controls, and Flame Safeguard


Questions and Answers

Chapter 12 Boiler Auxiliaries and External Water Treatment


Questions and Answers

Chapter 13 Boiler Water Problems and Treatment

Questions and Answers

Chapter 14 In-Service Problems, Inspection, Maintenance, and


Questions and Answers

Chapter 15 Boiler Plant Training, Performance, and Efficiency


Questions and Answers

Appendix 1 Terminology and Definitions

Appendix 2 Water Treatment Tables

Appendix 3 Observing Boiler Safety Rules

Appendix 4 Professional Organizations

Appendix 5 Jurisdictions

Appendix 6 Unit Conversions

Appendix 7 Steam Tables

Appendix 8 Bibliography



This book has been widely used by boiler personnel all over the world. From the classroom to the control room of any plant, it is an excellent reference for the boiler industry.

This fifth edition has been revised to include requirements of the latest codes of the American Society of Mechanical Engineers, the National Board of Boiler and Pressure Vessel Inspectors, and other national professional organizations. In addition, recent technological developments in the boiler industry have been included. Among the boilers with new technology are condensing boilers, hybrid boilers, solar heating boilers, and solar power generation boilers.

A list of professional organizations related to the boiler industry has been added to the book. The organizations’ contact information is included.

The jurisdictions that have operating engineer licensing laws have been updated. Also, the jurisdictions that have boiler and pressure vessel inspection laws have been completely revised. The contact information for the boiler inspection departments of states and major cities of the United States and provinces and territories of Canada has been added.

Also included in this fifth edition is an appendix showing unit conversions, which will come in handy when performing math calculations.

Extreme care was taken in revising the book. It covers the complete life cycle of the boiler, from design to repair, irrespective of the size of the plant. One chapter has been devoted to nuclear power plant generators, which are also designed under the ASME Boiler and Pressure Vessel Code.


Boiler Systems, Classifications, and Fundamental Operating Practices:

Modern Operation and Responsibilities:

Boiler plant operation, maintenance, and inspection requires the services of trained technical people because of the growth and technological development in new materials, metallurgical principles on why materials fail, welding in joining boiler components and in repairs, sensor development which permits more automatic control, and finally the application of computers in tracking boiler operations and conditions.

Boilers are used at many different pressures and temperatures with large variations in output and different fuel-burning systems. Designers and fabricators apply heat transfer principles to design a boiler system but must also have broad technical skills in fluid mechanics, metallurgy, strength of materials to resist stress, burners, controls, and safety devices for the boiler system, or as stipulated by Codes and approval bodies.

The skill and knowledge required of operators may vary because installations range from simple heating systems to integrated process and utility boiler systems. Operating controls can vary from manual to semiautomatic to full automatic. The trend is to automatic operation.

However, experienced operators always study the boiler plant layout so that the components, auxiliaries, controls, piping, and possible emergency procedures to follow are thoroughly understood. The study should include a review of the fuel, air, water and steam, and fuel-gas loops, and the assigned limitations each may have in operation.

Operators must be familiar with modern boiler controls that are based on an integrated system involving controlling:

  1. Load flow for heat, process use, or electric power generation.
  2. Fuel flow and its efficient burning.
  3. Airflow to support proper and efficient combustion.
  4. Water and steam flows to follow load.
  5. Exhaust flow of products of combustion.

The highly automated plant requires the knowledge of how the system works to produce the desired results, and what to do to make it perform according to design. Manual operation may still be required under emergency conditions, which is why a knowledge of the different “loops” of a boiler system will assist the operator to restore conditions to normal much faster. With the growing use of computers, if a boiler system is out of limits, skilled personnel must trace through the system to see if the problem is in the instruments or out-of-calibration actuators or if a component of the system has had an electrical or mechanical breakdown.

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